Better (really) late than never update, since it's always disappointing when I can't find people's results when searching the archive:
We made our own records to specs found online out of black ABS... chucked 'em into drill press and etched the grooves with a hot scratch awl, and then cut each to pieces on the bandsaw. Decided to go halfway between realism and not having a million pieces - the
effect was what mattered and it definitely had a great
effect (even applause at Tech). Made a few solids, and enough breakaways for a weekend, plus an extra. When crew cleaned up, they stacked pieces, separating each night, and during the week the shop did the jigsaw puzzles with spots of super glue. Had one
snap in actor's hands, but it was because she twisted it. Worked pretty well for the supplies price, although the superglue's melting of the ABS required some filing down to make sure the gaps stayed slim. Making all the records (and even jackets) ourselves definitely helped the
effect as there was no visual difference between real and
props (other than the non breakable's labels were green, and the breakable was red